Boiler Data

10/09/12 6:00 PMCondensate extraction pump

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TABLE OF CONTENTS

1 MAIN BOILER1.1 GENERAL SPECIFICATION1.2 DESIGNATION1.3 FURNACE SPECIFICATION1.4 WATER WALLS

1.4.1 FRONT WALLS1.4.2 SIDE WALLS, REAR WALLS1.4.3 WATER WALL HEADERS

1.5 DRUM1.6 SUPERHEATERS1.7 RE HEATERS1.8 SUPER HEATER AND RE HEATER TEMP. CONTROL

1.8.1 SUPER HEATER ATTEMPERATOR1.8.2 RE HEATER EMERGENCY TEMP. CONTROL ATTEMPERATOR

1.9 ECONOMISER1.10 BOILER WATER CIRCULATING PUMP

1.10.1 CHARACTERISTICS1.10.2 NORMAL OPERATING DUTY1.10.3 MOTOR CHARACTERISTICS1.10.4 WEIGHTS (APPROXIMATE)1.10.5 CC PUMP OVERHEAD TANK1.10.6 CC BOOSTER PUMP

2 MILL SYSTEM2.1 MILL2.2 MILL MOTOR2.3 MILL BEARINGS2.4 MILL EXTERNAL LUBRICATION SYSTEM2.5 RAW COAL FEEDER

2.5.1 Feeder2.5.2 Motor2.5.3 Clean out conveyor

2.6 MILL REJECT SYSTEM2.7 COAL PIPING & BURNERS

2.7.1 COAL PIPING2.7.2 COAL BURNERS2.7.3 OIL FIRING

3 INDUCED DRAFT FAN (ID FAN)3.1 FAN3.2 FAN DESIGN RATING3.3 FAN RESERVE3.4 VARIABLE FREQUENCY DRIVE (VFD)

3.4.1 Channel Rating3.4.2 VFD Transformers3.4.3 VFD Reactors (Both Channel 1 & 2)



3.4.4 VFD Motor Exciter3.4.5 COUPLING3.4.6 FAN BEARINGS3.4.7 MOTOR3.4.8 LUBE OIL SYSTEM

4 FORCED DRAFT FAN (FD FAN)4.1 FAN4.2 FAN DESIGN RATING4.3 FAN RESERVE4.4 COUPLING4.5 FAN BEARINGS4.6 MOTOR

4.6.1 Motor Bearing4.7 LUBE OIL SYSTEM

4.7.1 Pump4.7.2 Lube Oil Filter4.7.3 Lube Oil Coolers

5 PRIMARY AIR FAN (PA FAN)5.1 FAN5.2 FAN DESIGN RATING5.3 FAN RESERVE5.4 FAN DRIVE COUPLING

5.4.1 FAN BEARINGS5.4.2 MOTOR5.4.3 Motor Bearing

5.5 PA LUB OIL SYSTEM5.5.1 Pump5.5.2 Lube Oil Filter5.5.3 Lube Oil Cooler

6 SCANNER AIR FAN6.1 FAN6.2 A.C. MOTOR6.3 D.C. MOTOR

7 PRIMARY AIR PREHEATER (PAPH)7.1 ELEMENTS7.2 MAIN DRIVE7.3 AUXILIARY DRIVE7.4 BEARINGS

7.4.1 Support Bearing7.4.2 Guide Bearing7.4.3 SOOT BLOWERS7.4.4 BEARING HOUSING OIL CAPACITY7.4.5 COOLERS

8 SECONDARY AIR PRE-HEATER (SAPH)8.1 ELEMENTS8.2 MAIN DRIVE



8.3 AUXILIARY DRIVE8.4 BEARINGS

8.4.1 Support Bearing8.4.2 Guide Bearing

8.5 SOOT BLOWERS8.6 BEARING HOUSING OIL CAPACITY8.7 COOLERS

9 STEAM COIL AIR PREHEATER (SCAPH)9.1 PRIMARY STEAM COIL APH9.2 SECONDARY STEAM COIL APH

10 ELECTRO STATIC PRECIPITATOR10.1 DESIGN CONDITION10.2 COLLECTING ELECTRODES10.3 EMITTING ELECTRODES10.4 GAS DISTRIBUTION SYSTEM

10.4.1 Inlet10.4.2 Outlet

10.5 HV RECTIFIER10.6 MOTOR FOR RAPPING EMITTING ELECTRODES

10.6.1 MOTOR FOR RAPPING COLLECTING ELECTRODES10.6.2 MOTOR FOR RAPPING GAS DISTRIBUTION SYSTEM10.6.3 RAPPERS FOR COLLECTING ELECTRODE10.6.4 RAPPERS FOR EMITING ELECTRODES

10.7 HOPPERS10.7.1 Hopper Specification10.7.2 Heating Elements for Hopper10.7.3 Heating Elements For Shaft Insulators10.7.4 Support Insulators

11 SOOT BLOWER12 H.P. DOSING PUMP

12.1 MIXING TANK12.2 METERING TANK12.3 DOSING PUMPS

13 BLOW DOWN VESSELS14 PRESSURE REDUCING AND DESUPERHEATING STATION (PRDS)

14.1 PRDS STATION14.1.1 HT & LT PRDS14.1.2 MS & CRH PRDS14.1.3 7.2 PRDS STATION SAFETY VALVES

15 EXPRESS LAB (SWAS)15.1 SPECIFIC CONDUCTIVITY15.2 CATION CONDUCTIVITY15.3 PH15.4 DISSOLVED OXYGEN15.5 SILICA



15.6 PHOSPHATE15.7 HYDRAZINE15.8 SODIUM15.9 CHLORIDE

16 CONDENSATE EXTRACTION PUMP16.1 MOTOR SPECIFICATION16.2 PUMP SPECIFICATION16.3 CONSUMPTION AT DESIGN CONDITION16.4 CEP SUCTION STRAINER

16.4.1 Operating Condition16.4.2 Performance Condition16.4.3 Design Condition

16.5 SEALING WATER REQUIREMENT

17 TURBINE DRIVEN BOILER FEED PUMP17.1 BOOSTER PUMP17.2 MAIN PUMP

17.2.1 Direction of rotation from Booster Pump to BFP17.3 TURBINE17.4 TDBFP- GEAR BOX17.5 OIL SYSTEM17.6 OIL VAPOR EXTRACTOR FANS17.7 OIL PUMPS SPECIFICATION17.8 OIL PURIFIER (CENTRIFUGE)17.9 TDBFP GOVERNING SYSTEM

17.9.1 Governing Rack17.9.2 Emergency Stop Valve (ESV)17.9.3 Main Control Valve (MCV)17.9.4 Aux. Control Valve (ACV)17.9.5 Accumulators17.9.6 Hydraulic Pressure Accumulator17.9.7 Material

17.10 TDBFP TWIN OIL COOLER17.10.1 Design Data17.10.2 Weights17.10.3 Materials

17.11 FLEXIBLE COUPLING17.11.1 Specification17.11.2 Coupling capacity

17.12 POWER PACK ASSEMBLY17.13 OPERATING CONDITION

18 MOTOR DRIVEN BOILER FEED PUMP18.1 BOOSTER PUMP18.2 MAIN PUMP18.3 MOTOR18.4 HYDRAULIC COUPLING18.5 FLEXIBLE COUPLING (91069-00) MOTOR HC

18.5.1 Specification18.5.2 Coupling Capacity



18.6 OIL PUMP18.7 LUBRICATING OIL SPECIFICATION18.8 OIL COOLERS18.9 LUB OIL REQUIREMENT IN BRGS18.10 OIL PURIFIER FOR MDBFP18.11 OPERATING PARAMETER18.12 BFP CONICAL STRAINER

18.12.1 Operating Condition18.12.2 Performance Condition18.12.3 Design Condition

19 DEAERATOR AND FST19.1 DEAERATOR HEADER ASSEMBLY

19.1.1 Materials19.2 FEED WATER STORAGE TANK

19.2.1 Materials19.2.2 Weights

19.3 DEAERATOR SAFETY VALVES

20 SEAL OIL SYSTEM20.1 AC SEAL OIL PUMP (AIR SIDE) 2NO FULL CAPACITY

20.1.1 Pump specification20.1.2 Motor specification

20.2 DC SEAL OIL PUMP (AIR SIDE)20.2.1 Pump specification20.2.2 Motor specification

20.3 SEAL OIL COOLER (AIR SIDE)20.4 SEAL OIL COOLER (GAS SIDE)20.5 AS SEAL OIL FILTER20.6 H2 SEAL OIL FILTER

21 TG LUBE OIL SYSTEM21.1 LUBE OIL PUMPS SPECIFICATION

21.1.1 Pumps specification21.1.2 Motor specification

21.2 MATERIALS

22 HP HEATERS22.1 HPH-5A & 5B

22.1.1 Weight (kg)22.1.2 Details (stand Pipe)

22.2 HPH-6A & 6B22.2.1 Weight (kg)22.2.2 Details (stand Pipe)

22.3 HP HEATERS SPECIFICATION22.4 MATERIALS22.5 SAFETY VALVE

23 CONTROL FLUID23.1 FIRE RESISTANT FLUID SPECIFICATION23.2 CONTROL FLUID TANK



23.3 CONTROL FLUID PUMPS23.3.1 Pump specification23.3.2 Motor specification

23.4 CONTROL FLUID COOLER23.4.1 Design pressure23.4.2 Hydraulic test23.4.3 Weight

23.5 CONTROL FLUID PUMP MOTOR SET23.5.1 Low Pressure Pump23.5.2 High Pressure Pump

23.6 CHANGE OVER DOUBLE FILTER23.6.1 Design requirement23.6.2 Flow across Filter23.6.3 Pressure Drop across filter

23.7 REGENERATIVE SYSTEM (C.F. PURIFICATION)23.7.1 Filters (Filters Philipp, France)23.7.2 Heating unit23.7.3 Regenerative pumps (C.F. Recirculation PP)23.7.4 Pump specification23.7.5 Motor specification

24 MAIN TURBINE24.1 MAIN TURBINE

24.1.1 Specifications24.1.2 Weights (tons)24.1.3 Size of bearing

24.2 MATERIAL OF CONSTRUCTION24.2.1 Turbine Casings24.2.2 Blades (Moving)24.2.3 Rotors

24.3 IP TURBINE CASING24.3.1 Outer casing24.3.2 Chamber-2

24.4 IP TURBINE ROTOR24.5 LP SHAFT

24.5.1 Material24.6 TURBINE EXTRACTIONS24.7 OPERATING PARAMETER

24.7.1 Steam Pressure And Temperatures (Rated)24.7.2 Casing temperature limiting values24.7.3 Permissible temperature difference between parallel steam supply lines24.7.4 Feed heater out of service24.7.5 Out put limit with ATT24.7.6 Motoring24.7.7 Low vacuum trip standard settings24.7.8 Barring gear

24.8 TURBOVISARY PARAMETER24.8.1 Axial Shift24.8.2 Differential Expansions24.8.3 Vibration



24.8.4 Bearing temperature24.8.5 Fixed Points

24.9 HEAT BALANCE DATA24.10 TURBINE LOAD SHARING CAPACITY

25 TURBINE SEAL STEAM SYSTEM25.1 SEAL STEAM

25.1.1 Exhauster Fans specification25.1.2 Motor specification25.1.3 Seal stem pressure control valve

26 CENTRAL LUB OIL STORAGE & PURIFICATION UNIT26.1 CLEAN OIL TANK

26.1.1 Material26.2 DIRTY OIL TANK

26.2.126.3 OIL TRANSFER PUMPS


26.4 CENTRAL OIL PURIFIER26.4.1 Centrifuge26.4.2 Centrifuge Feed Pump26.4.3 Centrifuge Motor26.4.4 Centrifuge Materials

27 FLASH TANKS27.1 HP FLASH TANK

27.1.1 Material27.2 STEAM DRAIN FLASH TANK27.3 FEED WATER HEATER SAFETY V/V DISCHARGE FLASH TANK

28 EQUIPMENT COOLING WATER SYSTEM28.1 ECW TANK (TG)28.2 EQUIPMENT COOLING WATER PUMP

28.2.1 ECW (SG)28.2.2 ECW (TG)

28.3 PLATE HEAT EXCHANGER28.3.1 TG28.3.2 SG

29 AUXILIARY COOLING WATER SYSTEM29.1 AUXILIARY COOLING WATER PUMP29.2 GA & CROSS SECTION SELF CLEANING STRAINER (SCS)

29.2.1 Design Data29.2.2 Details of Flushing Pump Skid SCS

30 VACUUM RAISING SYSTEM30.1 VACUUM PUMP


30.2 RECIRCULATING PUMP



30.2.1 Pump specification30.2.2 Motor specification30.2.3 Material

30.3 SEPARATOR TANK

31 PRIMARY WATER SYSTEM31.1 PRIMARY WATER PUMP31.2 PRIMARY WATER FILTER

32 OFF SITE AREAS32.1 PTCW SYSTEM

32.1.1 Raw water transfer pump32.1.2 Electric motor32.1.3 Booster pump (For Raw water pump lubrication)32.1.4 Electric motor- Raw water booster pump32.1.5 Reactor clarifier32.1.6 CLARIFIED WATER SYSTEM

32.2 FIRE HYDRANT SYSTEM32.2.1 SPRAY SYSTEM32.2.2 JOCKEY PUMP32.2.3 BOOSTER PUMP HYDRANT LINE32.2.4 AIR COMPRESSOR ( 2 NO)



1 MAIN BOILER1.1 GENERAL SPECIFICATION

Manufacturer

M/s. BHEL (C.E.Design.)

Type

Controlled Circulation With Rifled Tubing,Dry-Bottom, Radiant Reheat, Single Drum, Top Supported, Balanced DraftFurnace.

Type of Firing

Tilting Tangential.

Minimum Load At Which SteamGenerator Can Be OperatedContinuously With Complete Flame Stability Without Oil Support

(%MCR)

30%

1.2 DESIGNATION 19177 301-51 CC +


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15797 230-511.3 FURNACE SPECIFICATION

Type Balanced Draft Furnace with Fusion WeldedW/W.

Wall Water steam cooledTube arrangement MembraneResidence time for fuel particles inthe furnace

3 Secs.

Effective volume used to calculatethe residence time

16900 M3

Depth 15.797 MWidth 19.177 MFurnace Volume 16900 M3Drum elevation 76.38 MFuel Heat input 1231.3 X 106 KCal/hr.

1.4 WATER WALLS

Total heating surface area 4837 M2Total Water wall Tube 1062 Nos.

1.4.1 FRONT WALLSOD 51.0 mmPitch 63.5 mmMWT 5.6 mmMaterial SA 210 GrcMethod of joining long tube Fusion WeldedTotal Wt. of Walls 185320 kg.Design Pr. of tubes 217.8 kg/cm2Design temp. 398 oC

1.4.2 SIDE WALLS, REAR WALLS Side Walls Rear Walls Extended SW, Corner

Arch, Screen And HangerOD 51 mm 51 and 63.5 mmPitch 63.5 mm 63.5 and 76.2 mmMinimum Wall thickness (MWT) 5.6 mm 5.6, 7.6 and 11 mmMethod of joining long tubes Butt weld But WeldDesign Pressure of tubes 217.8 kg/cm2 (g) 217.8 kg/cm2 (g)Design temp. 398oC 398oCMaterial SA210 Grc SA 210 Grc

1.4.3 WATER WALL HEADERS Lower drum WW Outlet HeadersNumber 1 5Outside dia 914.4 mm 273.0 mmThickness 95 mm 40.0 and 50.0 mmTotal Wt. of headers 172.0 (T) 31.0 (T)Design Pressure of headers 217.8 kg/cm2(g) 213.0 kg/cm2(g)Material specification SA-515 Gr.70 SA-106Gr.CDesign temperature 370oC 370oC



1.5 DRUMMaterial Specification SA-299Design Pressure 207 kg/cm2(g)Design metal temp. 368 oCOperating Pressure 193 kg/cm2 (g)Actual thickness 210/175 mm.Overall length of drum (with dishends)

24216 mm

Internal dia 1778 mmCorrosion allowance 0.75 mmNo. of Down Comers 6 nos.No. of Cyclone Separators 92No. of driers 124Shroud material Carbon SteelBoiler Drum Wt. (withoutinternal)

233.3 (MT)

Boiler Drum Wt. (with internals) 243.292 (MT) 1.6 SUPERHEATERS

Ltsh(Stage # I)

Divisional Panel(Stage # II)

Platen(Stage # III)

Material SA 213 SA 213 SA 213Type Convective Radiant RadiantDrainable / Non-drainable Drainable Non-drainable Non-drainableEffective Heating Surface area 6018 M2 1319 M2 1385 M2OD 44.5 mm 44.5 mm 51.0 mmTotal no. of assembly 124 48 25Total no. of tubes 744 432 400Temperature 0C 493 513 592

1.7 RE HEATERSType Radiant Front Platen, Convective Rear Pendant.Total heating surface area 6864 M2Design Pressure 52.4 kg/cm2(g)No. of assembly 74No. of element 888Tube OD 54.0 mm

1.8 SUPER HEATER AND RE HEATER TEMP. CONTROL

1.8.1 SUPER HEATER ATTEMPERATOR

Type Spray type pressure atomized.Stage OnePosition in steam circuit Between LTSH and Divisional Panel S/HSpecification of material SA 335P12Control temperature 540oCControl Range 910 1675 T/Hr.Maximum Water Flow 45 Tons/hr. at 174oC

1.8.2 RE HEATER EMERGENCY TEMP. CONTROL ATTEMPERATOR



Type

Spray type pressure atomized.

Manufacturer BHEL, Trichy

Position in steam circuit CRH LineControl temp. Range 540oCControl Range 827 1393 T/Hr.R/H Normal temp. control Burner tilting and Excess air.

1.9 ECONOMISER

Type Plain Tube Non-steaming.Horizontal Heating Surface Area 18200 M2Design Pr. of tubes 217.8 kg/cm2(g)OD of tubes 51.00 mmMinimum thickness tubes 6.2 mmLength of tubes 296.4 MPitch 101.6 mm (SL)

136.0 mm (ST)No. of blocks 3 Nos.Assembly 130Element 276Design temp. 334oCASME Specification SA210 Gr A1Gas flow Path area

131 M2

1.10 BOILER WATER CIRCULATING PUMP Number 3 (2W + 1S)

1.10.1 CHARACTERISTICSType Single Suction double discharge.Size (2x13) X 16 X 19 HDesign Pressure 212 kgf/cm2Design Temperature 370oC

1.10.2 NORMAL OPERATING DUTYSuction Pressure 191.6 kgf/cm2Pumping temp. 365oCQuantity Pumped 3018 m/hrDifferential Pressure 3.12 kgf/cm2Minimum NPSH required Above Vapor Pressure 19 m (3% head drop)Pump efficiency 84% Hot DutyPower absorbed 195 KW Hot duty 347.8 KW Cold Test.

1.10.3 MOTOR CHARACTERISTICS



Type Wet Stator squirrel Cage induction.Output 350 KWService Factor 1.0Winding Insulation XLPMotor Case design. Temperature 343oC Hot Duty Cold Test Motor efficiency 88.6% 90.5%HP input 315 522.7Power factor 0.69 0.810Overall efficiency 74.4% 76%Full load speed 1450 RPMFull load current 84 Amps.Motor starting current 240 Amps.

1.10.4 WEIGHTS (APPROXIMATE)Pump casing 4600 kg.Motor complete 6700 kg.Heat exchanger 9000 kg.Total 12000 kg.

1.10.5 CC PUMP OVERHEAD TANKType 2500 X 12Make Trichy, BHELCapacity 19.0 m3

Temp. 50oCWorking Pressure 7 kg/cm2

Test Pressure 10.5 kg/cm2

1.10.6 CC BOOSTER PUMPPump Head 50 mSpeed 2900 RPMFlow 9 m3/hr.MotorFrame ND 150 LSpeed 2920 RPMCurrent 26 Amp.Rating 15 to 20 KWInsulation Class F

2 MILL SYSTEM2.1 Mill Type of Pulverizer Bowl Mills XRP 1003No. of Mills / Boiler 10No. of Mills for Design Coalat 100% BMCR 7Design capacity of mill 66.3 Tons/hr. for Pulverized fuel fineness 70% through 200 mesh with a Raw coal of Grindability. Index 55 HGI and total moisture of 14%.



Speed of Pulveriser 600Motor rating 525 KW 2.2 Mill Motor

Manufacturer BHEL, BHOPALMotor type Cage Rotor a synchronous MotorDirection of rotation as viewedfrom NDE

Standard continuous rating at40oC ambient temp. as per Indianstandard

525 KW

Rated Voltage 3300 VSpeed 600 RPMFull load current 137 AmpNo load current(A) 75 Amp

2.3 Mill Bearings

Drive End Non-Drive End(a) Type NU 236

62 36MC3NU 236

(b) Recommended Lubricant Grease IOC Servogem - 3 2.4 Mill External Lubrication System Pumps 2X 100%Make AlektonType ScrewCapacity 70 LPMSpeed 970 RPMCoupling LovejoyMotor Manufacturer ABB

Rated out put & speed 3.7 KW, 960 RPMBearing make & type DE 6308ZZC3, NDE 6307ZZC3Full load current 8.3 A

2.5 RAW COAL FEEDER

2.5.1 FeederType 36 Gravimetric FeederCapacity Minimum - 16.4 T/Hr , Maximum - 82

T/Hr

Supplier BHELQuantity per Boiler 10Gear Ratio (main Drive) 138.24:1Gear Ratio (COC Drive) 1059.43:1Bulk density of coal. 55lbs/ft3Working pressure. 500mmwc



2.5.2 Motor

Rating

5.5 KW TEFC

Duty cycle

Continuous

Speed

1440 RPM

Current

11 .0 Amp.

Insulation Class

F

Duty SI

2.5.3 Clean out conveyor Rating & type 0.25 KW AC geared motorDuty Continuous S1Voltage rating 415 V , 3 phase , 50 HZSpeed 930 RPMFull load current 1.0 ampInsulation Class FMethod of starting DOLType of wt sensor Strain gauge type load cell(2 nos per feeder )Type of speed sensor Tachogenerator (2 nos per feeder)

2.6 MILL REJECT SYSTEM Bulk density T/ m3 1.6 Temperature 200 Total mill reject rate t/hr 0.7

Vessel vol cft 6 Air receiver, m3 10 Conveying air m3 /min 15.5 Motor Make NGEF

Rating 415 V+_6%50HZ Through transformer feeder

2.7 COAL PIPING & BURNERS



2.7.1 COAL PIPINGMaterial of Straight pipe Carbon SteelFuel Pipe diameter 658.8 mmFuel Pipe thickness 14.2 mm

2.7.2 COAL BURNERSType Tilting TangentialMake BHELNo. of coal burners feed by each mill 4 (Total no. of coal burners-40)No. of elevation of burners 10Temp. of coal Air mixture in PF Pipes 75 oC

2.7.3 OIL FIRING

2.7.3.1 HEAVY OIL BURNERSBurner Tilting tangential; Corner fired.Oil Gun Parallel pipe design, steam atomized.Atomiser External mixed; const. Pressure; steam atomized.Air Nozzle RectangularAtomiser Designation Spray plate 90J24Atomiser spray angle 90oCFuel Fuel oil to IS1593; 1971, LSHS oil, HPS oil.Capacity Maximum 7.5% MCR heat input per elevation.

30% MCR total.No. of oil guns 20 (4 per elevation).Location of oil guns Auxiliary air nozzles, AB, CD, EF, FG & HJ.Oil Firing rate maximum 2662 kg/hr/gunMinimum oil Firing rate 885 kg/hr/gunOil pressure at maximum Rating 9.5 kg/cm2 (g)Minimum allowable HFO pressure 3.0 kg/cm2 (g)Atomising steam flow at MaxMrating

205 kg/hr/gun

Atomising steam flow at minimumrating

257 kg/hr/gun

Oil viscosity at the gun 15 to 30 CSTSteam quality 10 to 15oC super heat.Atomising steam pressure 5.25 kg/cm2(g)

2.7.3.2 LIGHT DIESEL OIL BURNERSService Initial start up and warm up.Atomiser External Mixed, Constant Pressure, Compressed

Air Atomised.Fuel LDO to IS1460/1974Capacity (Max.) 7.5% MCR heat input and total 7.5% MCR.No. of oil guns 4Location of oil guns In Auxiliary air nozzle AB.LDO flow/gun(max/min Kg/hr) 2190/750Atomising air flow/gun(Max,Min,Scale)

165 / 210 / 245

Maximum Rating LDO Pressure 9.0 kg/cm2(g)



Minimum Rating LDO Pressure 3.0 kg/cm2(g)

Atomising air pressure .25 kg/cm2(g)

2.7.3.3 IGNITERSMake Unison Industries / USAService Oil burner light off.Type High Energy Arc IgniterLocation Burner Mounting PanelOutput Min 4 Spark / Second, 12 Joules/SparkInput 110V AC, 50 Hz.

3 INDUCED DRAFT FAN (ID FAN) 3.1 FAN

Type NDZV 47 SIDORMake BHELOrientation Inclined Suction Bottom Horizontal DeliveryMedium Handled Flue gasNo. per Boiler 2Location Out door

3.2 FAN DESIGN RATING

Capacity 593.32 m3/sec.Total head developed 485 mm WClTemp. of Medium 153oCSpecific Wt. of Medium 0.780 kg/m3

Speed 560 RPM 3.3 FAN RESERVE

Flow 44.9 %Pressure 79.9 %

3.4 VARIABLE FREQUENCY DRIVE (VFD)

3.4.1 Channel Rating Single Channel Dual ChannelSpeed (RPM) 400 560Current (Amp) 400 2 X 560Motor Voltage (V) 1796 2 X 2300Power (KW) 1465 4021



Power Factor (Ratio) 0.9 0.9

3.4.2 VFD Transformers Channel # 1 Channel # 2Rating (KVA) 3000 3000Voltage Transformation 11000 / 2300 V 11000 / 2300Vector Group Dd0 DYN11

3.4.3 VFD Reactors (Both Channel 1 & 2) Name Air Core ReactorRated Current 900 AmpInductance 10 milli Henry

3.4.4 VFD Motor Exciter Make BHELRating 34 KWExcitation Voltage 342 VExcitation Current 64 AmpConnection StarVolts 100 VCurrent 340 AmpSpeed 530 RPMFrequency 85 HzSpecification IS : 4722

3.4.5 COUPLING

Type SOFTType of Fan Regulation Inlet damper and variable Frequency Drive.

3.4.6 FAN BEARINGS

Fan fixed bearing 10 RTFan free bearing 10 RTPermissible bearing clearances Oil clearance 0.250 mm to 0.430 mmSide clearance 0.230 mm to 0.315 mmAxial thrust clearance 0.380 mm to 0.760 mmCooling water flow for the fan 4.0 m3 per hour / Brg.



Brgs

Note :- Cooling Water Flow Is Based On 32oc Ambient And 32oc Water InletTemperature.

3.4.7 MOTOR

Manufacturer BHEL, BHOPALFrame size 1DQ 4342Type Max Synchronous Motor 2 X 2300 VRating 4021 KW (both channels together)Speed 56 RPM to 560 RPMPF 0.9 LeadInsulation Class FConnection Double starMax. Stator Voltage 2 X 2300 VMax. Stator Current 2 X 5807AType of Duty ContinuousType of Exciter BrushlessExciter Rotor Voltage 116 V D.C.Exciter Rotor Current 300 Amp. D.C.Exciter Stator Current 80 A (3j)Exciter Stator Voltage 415V AC (3j)

Stator Winding Connection Y (Star)

3.4.8 LUBE OIL SYSTEM

3.4.8.1 Pump

Oil tank capacity 80 liters/minPump type Screw PumpNo of pumps 2Motor Rating 3 Phase, 415V,2.2KW, 50 Hz.Speed 2900 RPMNormal Design Pressure 5.0 kg/cm2No. of Lube Oil Cooler / Boiler 4 (2 Working + 2 Standby)Quantity of Cooling Water / Boiler 265 LPMLube Oil Quality ISO-VG-68Relief Valve Setting 6.0 kg/cm2

3.4.8.2 Oil filtersType Basket typeMesh material SS Rating 60 micronsWorking pressure 5 kscCapacity 150 Lpm



3.4.8.3 Heat ExchangerDesign pressure Shell side 8 ksc, Tube side 7 kscCapacity 80 LpmHeat exchange capacity 21600 Kcal/Hr

4 FORCED DRAFT FAN (FD FAN)4.1 FAN

Type AP1 26/16 Axial fan, constant speed, aerofoil,single stage with silencer & aerofoil assembly insuction ducting.

No. Per Boiler TwoMake BHEL Ranipet


Capacity 261.6 m3/sec.Total head developed 391 mmwcMedium handled Atmospheric AirLocation Out doorOrientation Vertical Suction Horizontal Delivery.Temp. of medium 50oCSpecific wt. of medium 1.0334 kg/m3Fan Speed 980 RPMFan Regulation Blade pitch controlFan Weight 27 Tonnes

4.3 FAN RESERVE

Flow 68.6%Fan Pressure 96.5%

4.4 COUPLING

Type Regiflex Coupling.

4.5 FAN BEARINGS

Fan Fixed bearing Cylindrical Roller Brg NU 248C3 + 7248Fan Free bearing Cylindrical Roller Brg NU 248C3

4.6 MOTOR

Manufacturer M/s. BHEL, BHOPALMotor type SCIM,IS 325:1978 standards.Frame size 1LA7803-6,Continous duty.Fan Speed 980 RPM



Direction of rotation as viewedfromNon-driving end

Clockwise

Standard continuous rating at40oCAmbient temp. as per IndianStandard

1300 KW

Standard continuous rating at50oC

3300 KW

Rated Voltage (Volts) 11 KVPermissible Variation of (a) Voltage (Volts) 10 %(b) Frequency (Hz) 50 + 3 %, -5% Combined Voltage andfrequency

10 % (Abs)

MinM Permissible StartingVoltage (V)

8800 (80 % RV)

Speed at Rated Voltage and Freq. 995 RPMAt Rated Voltage and Frequency Full load current 84.2 Amps.No load current 34 Amps.Without driven equipment coupled 1.5 Seconds.With driven equipment coupled 15 Seconds.

4.6.1 Motor BearingType AntifrictionRecommended Lubrications OIL -IOC servogem-3 or equivalent

lubricated(grease0Lubrication Self

4.7 LUBE OIL SYSTEM

4.7.1 Pump

Oil Tank capacity 1300 LittersPump type Screw PumpMotor Rating 3j, 415V, 9.3KW, 50 HzSpeed 2870 RPMDesign Pressure 12 kg/cm2

No. of Oil Cooler / Boiler 3 (2 working + 1 standby)Quantity of Cooling Water /Boiler

430 LPM

Relief v/v setting 13.5 kg/cm2

System discharge capacity 175.0 LPM

4.7.2 Lube Oil FilterType Basket typeMesh material SS Rating 60 microns



Working pressure 12 kscCapacity 350 Lpm

4.7.3 Lube Oil Coolers Design pressure Shell side 15 ksc, Tube side 8.75 kscCapacity 175 LpmHeat exchange capacity Kcal/HrTemperature limits Shell-80 0C , Tube-80 0C

5 PRIMARY AIR FAN (PA FAN)5.1 FAN

Type AP2 20/12No. per boiler 2Orientation Vertical Suction Horizontal DeliveryMedium Handled Atmospheric AirLocation Out doorType of Regulation Blade Pitch Control


Capacity 170 .5m3/sec.Total head developed 1183 mm WClTemp. of medium 50oCSpecific Wt. of Medium 1.0508 kg/m3Speed 1480 RPM

5.3 FAN RESERVE

Fan Flow 84.5 %Fan Pressure 35.2%

5.4 FAN DRIVE COUPLING

Type of coupling Rigiflex coupling

5.4.1 FAN BEARINGS

Fan Fixed bearing 7040 C3Fan Free bearing NU 236 C3Fan weight 1300 Tons

5.4.2 MOTORType SQ CageManufacturer BHEL, BHOPALType of Duty S1Direction of rotation as viewedfromNon-drive end

Anti clockwise

Rated Voltage 11,000 VoltsStandard continuous rating at 1817 KW



40oC ambient temp. as per IndianStandardDerated rating for specifiednormal condition i.e. 50oC ambienttemp.

2450 KW

Permissible Variation of

Voltage 10% VoltsFrequency 5% HzRated Speed at Rated Voltage andFrequency

1494 RPM

At rated Voltage and Frequency Full Load current 107 Amps.No Load current 30 Amps.Starting time with minimumPermissible Voltage of 80% RV

Without Fan 2.0 sec.With Fan 18.0 sec.

5.4.3 Motor Bearing

Bearing DRIVE END NON-DRIVE ENDType Ball and Roller RollerRecommended Lubricant Grease IOC Servogem 3

5.5 PA LUB OIL SYSTEM

5.5.1 PumpOil tank capacity 600 litersPump Screw PumpMotor Rating 3 Phase, 415V, 7.5KW, 50 HzSpeed 2870 RPMDesign Pressure 12 kg/cm2Lube Oil Quality 150 VG 68Relief Valve Setting 13.5 kg/cm2Pump discharge 80 LPMNo. of Lube Oil Cooler / Boiler 4 (2 Working + 2 standby)Quality of Cooling Water / Boiler 265 LPM

5.5.2 Lube Oil FilterType Basket typeMesh material SS Rating 60 micronsWorking pressure 12 kscCapacity 160 Lpm

5.5.3 Lube Oil CoolerDesign pressure Shell side 15 ksc, Tube side 8.75 kscCapacity 80 LpmHeat exchange capacity xxxx Kcal/HrTemperature limits Shell-80 0C , Tube-80 0C



6 SCANNER AIR FAN 6.1 FAN

No. 2 (One is AC driven + One D.C. driven , 100%standby)

Type of Fan Radial Backward curved Blade Single SuctionManufacturer DOCTAIRE HPSC 315 SWSIBoosting Pressure 200 mmWCEfficiency of the fan 72 %Power consumption 6.08 KWFan Speed 1455 RPMCapacity 8000 CMHDensity 1.09

6.2 A.C. MOTOR

Make Crompton Greaves Ltd.Type & Frame Size TEFC, Squirrel Cage Induction MotorRating 9.3 KWFull Load Current 17.5 Amp.Efficiency 88%Speed 1460 RPM

6.3 D.C. MOTOR

Make Kirloskar Electric Co. Ltd.Frame Size TDC 225 LDuty S1Insulation F ClassRating 9.30 KWCurrent 51 Amp.Speed 1450 RPM

7 PRIMARY AIR PREHEATER (PAPH)Make BHELType Ljungstrom Bisector (Regenerative)Air heater size 30 VIM 2000No. of Air Pre-heater 2 per Boiler

7.1 ELEMENTS



END HEIGHT OF

ELEMENTMATERIAL DESCRIPTION OF

ELEMENTSHOT 850 mm Carbon Steel Double CorrugatedINTER 850 mm Carbon Steel Double CorrugatedCOLD 300 mm Carbon Steel Notched Flat

7.2 MAIN DRIVE

Electric Motor Squirrel Cage, induction motor, 11KW, 415V, 3j,50hZ, 1450 RPM, Frame size 160-L, InsulationClass-F

Speed Reducer Ratio 110 : 1Speed Reducer Type-IA (3 in put) ;up shaftFinal Speed 1.42 RPM

7.3 AUXILIARY DRIVE

Air Motor 3KW, 3020 RPM, Air flow 0.18 NM3/Sec. at inletPressure of 6.33 kg/cm2

7.4 BEARINGS

7.4.1 Support BearingType Spherical Roller thrust bearing, No.294/500 SKF /

FAG.Lubrication SERVOCYL C680Drive 0.75KW, 415V, 3j, 50Hz, 1425 RPM, Class - F

Insulation.Pump Screw Pump (15 liter/Min.)

7.4.2 Guide BearingType Spherical Roller bearing, No.23060 CCK C3 / W33

SKF/FAG.Lubrication SERVOCYL C680Drive 0.55KW, 3j, 50Hz 415V, 910 RPM, Insulation

Class - FPump Screw Pump (15 liter/min.)

7.4.3 SOOT BLOWERSType of nozzle TwinType of drive SweepLocation Gas OutletQuantity 2 / APHMedium Steam at 340oC and 14 kg/cm2(g) and 2100 kg/hr.Motor 0.18 KW, 3j, 50Hz, 415V, 1380 RPM, Insulation

Class FReduction Ratio 4900 :1



7.4.4 BEARING HOUSING OIL CAPACITYGuide Brg. Housing 25 litersSupport Brg. Housing 90 liters

7.4.5 COOLERSGuide bearing Oil Cooler Flow 2 M3/Hr./Blr.Support bearing Oil Cooler Flow 2M3/Hr./Blr.

8 SECONDARY AIR PRE-HEATER (SAPH)

Make BHELType Ljungstrom Bisector (Regenerative)Size 30.5 VIM 2000

8.1 ELEMENTS

END HEIGHT OFELEMENT

MATERIAL DESCRIPTION OFELEMENTS

HOT 850 mm Carbon Steel Double CorrugatedINTER 850 mm Carbon Steel Double CorrugatedCOLD 300 mm Carbon Steel Notched Flat

8.2 MAIN DRIVE

Electric Motor Squirrel Cage induction motor, 18.5KW, 415V, 3j,50hZ, 1475 RPM, Insulation Class-F

Speed Reducer Ratio 130.36 : 1Speed Reducer Type-2, input Down Shaft.Final Speed 1.12 RPM

8.3 AUXILIARY DRIVE

Air Motor 3KW, 4070 RPM, Air flow 0.22 NM3/Sec. at InletPressure of 6.33 kg/cm2(g).IEC DUSTERLOH-IPM 400/8:1COUPLING BIBBY

8.4 BEARINGS

8.4.1 Support Bearing

Type Spherical Roller thrust bearing. 294/750E Lubrication Forced Oil Servocyl C680 Drive 0.75KW, 415V, 3j, Class - F Insulation. Pump Screw Pump (15 liter/min.)

8.4.2 Guide Bearing Type Spherical Roller bearing.23072 CCK Lubrication Forced Oil Servocyl C680



Drive 0.55KW, 3j, 50Hz 415V, Insulation Class - F Pump Screw Pump (15 litre/min.)

8.5 SOOT BLOWERS

Type of nozzle TwinType of drive SweepLocation Gas outletQuantity 2 / APHMedium Steam at 340oC and 14 kg/cm2(g) and 2100 kg/hr.Motor 0.18 KW, 3j, 50hZ, 415V, 750 RPM, Insulation

ClassBSpeed Reduction-4900:1

8.6 BEARING HOUSING OIL CAPACITY

Guide Brg. Housing 30 liters Support Brg. Housing

8.7 COOLERS

Guide bearing Oil Cooler Flow 2 M3/Hr./Blr.Support bearing Oil Cooler Flow M3/Hr./Blr.

9 STEAM COIL AIR PREHEATER (SCAPH) 9.1 PRIMARY STEAM COIL APH

No. of Steam Coil APH 2 Nos. per boilerSupplier M/s. Patels Air Temp. Ltd.Size of steam coil Air Preheater 2500 X 5200 X 250 mmInstalled Position verticalDesign Pressure 20kg/cm2 (ata)Design temp. 210oCHydraulic Test Pressure 30 kg/cm2Weight of one steam coil APH 3700 kg.



9.2 SECONDARY STEAM COIL APH

No. of Steam coil APH 2 Nos. per boilerSupplier M/s. Patels Air Temp. Ltd.Size of steam coil APH 3700 X 6000 X 250 mmInstalled Position VerticalDesign Pressure 20kg/cm2 (ata)Design Temp. 210oCHydraulic Test Pressure 30 kg/cm2Weight of one steam coil APH 5200 kg.

10 Electro Static Precipitator 10.1 DESIGN CONDITIONGas flow rate 821.5 m3/sec.Temperature 125oCInlet dust concentration 63.1 g/Nm3

Outlet dust concentration 35.8 mg/Nm3Type FAA-8 X 45-2X90130-2ESP efficiency 99.925%No. of precipitator offered per Boiler FourNo. of Gas Path per ESP OneNo. of Fields in seriesin each gas Path EightPressure drop across thePrecipitator for Design condition 15.0 mmwcVelocity of gas inside ESP 0.87 m/sec.Treatment Time 41.4 Secs. 10.2 COLLECTING ELECTRODES No. of rows of Collecting Electrodesper field 61No of collecting electrodes per field 366No of collecting electrodes arrangedin each row 6Total no. of Collecting Plates per Boiler 11,712Nominal height of collecting plate 13.0 MNominal length of collecting plate 750 mmSpecified Collecting Area 273.45 m2/m3/sec. 10.3 EMITTING ELECTRODES Type Spiral with hooksSize 2.7 mm diaNo. of electrodes in the frameforming one row 54No. of electrodes in each field 3,240Total no. of electrodes per Boiler 103680Total length of electrodes per field 13478.45



Plate / Wire spacing 150 mm (300 mm pitch) 10.4 GAS DISTRIBUTION SYSTEM

10.4.1 InletType & Quantity Perforated Plate 2 setsLocation Inlet of precipitator

10.4.2 OutletType & Quantity Thin sheets formed to a shape of U Located with 600 mm pitch- one setLocation Outlet of precipitator 10.5 HV RECTIFIER Rating 70 KV DC (Peak) 1200 mA DC (mean)Quantity per Boiler 16Type Silicon diode, Full Wave Bridge Connection.Location Mounted on the top of ESP 10.6 MOTOR FOR RAPPING EMITTING ELECTRODES Quantity 16 per ESP PassRating Geared motor, 0.33Hp, 2.5 RPM,3j , 415V, 50Hz.Location At the Roof of ESP.

10.6.1 MOTOR FOR RAPPING COLLECTING ELECTRODES Quantity 16 per ESP PassRating General motor, 0.33Hp, 1.1 RPM,3 j, 415V, 50Hz, ACLocation On the side panels of the casing.

10.6.2 MOTOR FOR RAPPING GAS DISTRIBUTION SYSTEM Quantity 8 TotalRating Geared motor, 0.33hP, 1.1 RPM,3 j, 415V, 50Hz, ACLocation On the GD housing.



10.6.3 RAPPERS FOR COLLECTING ELECTRODE No. and Type of Rappers One drop hammer per row of collecting electrodes having a collecting surface of

117 m2.

Rapper Size 4.9 Kgs Frequency of Rap Varying from 20 raps per hour at the inlet field to 1

rap/hour at the exit field. The frequency of rapping atintermediate fields can be adjusted between 20 and 1 perhour according to the requirement.

Drive Geared Electric motor.Location At the bottom of collecting electrodes.

10.6.4 RAPPERS FOR EMITING ELECTRODES No. and Type of Rappers: Approximately one drop hammer for two rows of Electrodes. Rapper Size: 3.0 KgsFrequency of rapping: 10 raps/hr.Drive: Geared electric motor.Location: On middle frames of emitting system frame work. 10.7 HOPPERS

10.7.1 Hopper SpecificationType PyramidalNo. of hoppers/ESP 32 per PassHeating Electrical heating provided at the bottom of the hopper.Baffling Arrangement 2 sets of deflector plates for each hopper.

10.7.2 Heating Elements for HopperQuantity per boiler 128 sets(18 Nos per hopper)Type Panel type 10kw/hopperRating 10kw/hopper,1 phase,V, 50 Hz,ACLocation At the bottom of the hoppers Thermostat setting for theTripping of the heat 120 C



10.7.3 Heating Elements For Shaft InsulatorsQuantity per ESP 16Rating 1.0 KW 1 phase,415V, 50 Hz,ACLocation In the shaft insulator housing

10.7.4 Support InsulatorsNos 641 Per BoilerRating 1.0 KW , 1 Ph , 415 V , 50 hz , ACLocation Support Insulator House

11 SOOT BLOWER

Source of steam for Soot Blowing Tap off from SH Divisional Outlet Header.Set Pressure on Pr. ReducingValve

30 kg/cm2(g)

Set Pressure on Safety valve 40 kg/cm2(g)Maximum flow rate 20 T/Hr.Temp. after Pr. reducing valve 374oC

Sl.No.

DESCRIPTION TYPE OF SOOT BLOWERSWB 1E LRD IIE

Blower Numbers 1 TO 88 105R TO108L

109R TO118L

119R TO129L



127R TO138L

Travel In MM 305 9700 9700 9700 Dead Travel In MM - 350 350 350 Nozzle Size In MM/ No. Off

Nozzlesj 26/1 j 32/2 j 25/2 j 25/2

Blowing Pressure In Kg/Cm2(G) 11 12.5 12.5 10 Speed Of Travel In MPM Rotary /

RPM6.1 0.7 1.55 5.87 1.55 5.87 1.55 5.87

Blowing Rate Per Group InKg/Min

89 303.2* 185 151

Blowing Time Per Group In Min 1.4 12.06 12.06 12.06 Operating Time Per Group In Min 1.5 12.5 12.5 12.5 Operating Time Per Cycle In Min 66 25 137.5 87.5 Steam Consumption Per Group In

Kg125 3657 2231 1821

Steam Consumption Per Cycle InKg

5500 3657 24542 7584

Cycles Per Day (Assumed) 3 3 3 3 Steam Consumption Per Day In

Kg16500 10971 73626 21852

Blowing Angle 360o 360o 360o 360o

(PER DAY) TOTAL STEAM CONSUMPTION IN Kgs = 122949 NOTE BLOWERS OPERATED IN A GROUP OF TWO. BLOWING RATE IS GIVEN FOR BLOWERS. LRD IIE LONG RETRACTABLE SOOT BLOWER ELECTRICALLY OPERATED. WB IE WALL BLOWER ELECTRICALLY OPERATED.

12 H.P. DOSING PUMP 12.1 MIXING TANK

Capacity 2200 LitersWeight 800 kg.Design temp. 60oCDesign Pr. 1.5 kg/cm2Mixing Motor 1.5 hpSpeed 925 RPMManufacturer Power Piping Company, Madras

12.2 METERING TANK



Capacity 2200 liters

Weight 750 kg.Temp. 60oCMotor capacity 1.5 hpSpeed 925 RPMManufacturer Power Piping Company, Madras

12.3 DOSING PUMPS

Make M/s. V.K. Pumps Industries Pvt. Ltd.Type Reciprocating Plunger type.Capacity 207 liter/hr.Pressure 230 kg/cm2No. of Pumps per boiler 2Fluid handled Trisodium PhosphateMotor Rating 5.5 K.W.Motor Speed 1500 RPMVolt 415V, 50 Hz, 3 PhaseInsulation F ClassCurrent 11 Amp.

13 BLOW DOWN VESSELS

IBD TANK CBD TANKNo. 1 1Type IBD Tank j2500x16 CBD Tank j2000x16Design Pr. 1.5 kg/cm2(g) 10 kg/cm2(g)Design temp. 111Oc 179OcHydraulic test Pr. 2.25 kg/cm2(g) 15 kg/cm2(g)Shell thickness 16 mm 16 mmShell dia 2500 mm 2000 mmWt. when empty 6625.578 kg. 4171.243 kg.Medium Steam & Water Steam & WaterMaterial Specification SA 515 Gr.70 SA 515 Gr.70

14 PRESSURE REDUCING AND DESUPERHEATING STATION (PRDS)

14.1 PRDS Station

14.1.1 HT & LT PRDS HT PRDS LT PRDSPressure 16 ata 16 ataTemperature 320oC 210 oCVolume of Steam 115 T/Hr 75 T/HrApplication TG Gland Sealing

BFP TurbineAH Soot blowingMill Inerting

Deareator PeggingHFO AutomisationSCAPH



14.1.2 MS & CRH PRDS MS CRHPressure 186.6 to 20.0 ata 52.4 to 20.0 ataTemperature 540 to 350 oC 360 to 350 oCVolume of Steam 92.5 T/Hr 10 T/Hr

Spray Required 10.6 T/Hr (200bar & 185oC)

8 T/Hr (200bar & 185oC)

14.1.3 7.2 PRDS STATION SAFETY VALVES Nos 3Rating All at 18 bar

15 EXPRESS LAB (SWAS) 15.1 SPECIFIC CONDUCTIVITY

Instrument Make Model RangeDM Makeup Water Conductivity

TransmitterPolymetron 8311

(K=0.1) /9125

0-10 s / CmCondensate Discharge after CPU 0-10 s / CmFeed water at Economiser Inlet 0-10 s / CmDrum water 0-10 s / CmSaturated Steam 0-10 s / CmSuperheated Steam 0-10 s / Cm

15.2 CATION CONDUCTIVITY

Instrument Make Model RangeDM Makeup Water Conductivity

TransmitterPolymetron 8310

(K=0.01) /9125

0-1 s / CmCondensate Discharge 0-1 s / CmCondensate Discharge after CPU 0-1 s / CmFeed water at Economiser Inlet 0-1 s / CmSaturated Steam 0-1 s / CmSuperheated Steam 0-1 s / Cm

15.3 PH

Instrument Make Model RangeDM Makeup Water PH

TransmitterPolymetron HA-425-60-

T-S7 / 91350-14 s / Cm

Condensate Discharge 0-14 s / CmCondensate Discharge after CPU 0-14 s / CmFeed water at Economiser Inlet 0-14 s / CmSaturated Steam 0-14 s / CmSuperheated Steam 0-14 s / Cm

Drum water 0-14 s / Cm



15.4 DISSOLVED OXYGEN

Instrument Make Model RangeCondensate Discharge Oxygen

AnalyserPolymetron 9182 0-50 ppb

Deaerator Outlet 0-20 ppbFeed water at Economiser Inlet 0-20 ppb

15.5 SILICA

Instrument Make Model RangeCondensate Discharge after CPU Silica

AnalyserPolymetron SILKOSTAT

88910-20 ppb

Drum Water (CBD) 0-500 ppbSuperheated Steam (MS) 0-20 ppb

15.6 PHOSPHATE

Instrument Make Model RangeDrum Water Polymetron PHOSPHAMAT

88920-2000 ppb

15.7 HYDRAZINE

Instrument Make Model RangeFeed water at Economiser Inlet Hydrazine

AnalyserPolymetron HYDROSTAT

91860-100 ppb

15.8 SODIUM

Instrument Make Model RangeCondensate Discharge Sodium

AnalyserPolymetron SODIMAT

90730-50 ppb

Condensate Discharge after CPU 0-50 ppb 15.9 CHLORIDE

Instrument Make Model RangeDrum Water Chloride

AnalyzerPABB CHLORIDE

82340-2000 ppb

16 CONDENSATE EXTRACTION PUMP 16.1Motor specification

Make BHEL BhopalRating 900 KW continuous dutyType Induction Motor (Squirrel cage)Voltage 11 KV 3 phaseNumber Of Poles 4Speed 1492 RPMFrequency 50 HzStator Current 58.5 Amps.



Insulation ClassDegree of protection

FIP55

Motor Winding Cooling Self Air-Cooled.Motor Brg. Type Anti FrictionMotor Bearing LubricatedDORSpace Heater ratingLube

IOC Servo Gem-3/EQV.Clockwise view from top800W, 240 VGrease, 50 gm for 4000 running hr

16.2Pump specificationManufacture BHEL, HyderabadPump designation EN6J 40/500No. Of Pumps 3 (50 % duty)Type Vertical canisterNumber of Stages 6Type of first impeller double suction NPSH Required 3.1 meter (4.2-1%, 4.4-0%)DOR (As Viewed From DE Side) CCWDesign flow rate 800m3/hrInlet temperature 49.2 0cSpecific gravity 0.9884Total discharge head 275mwcShut off head 361 mPump Speed 1492 rpmPower input to motor 763 kwEfficiency of Pump 81 %Minimum flow for continuous operation 300 m3 /hrRadial Bearing Cut less rubber, 8 Nos. 100 mm sizeCritical Speeds (RPM) 3380, 5798

16.3 Consumption at design condition Power Input At The Motor 763 KWLosses In The Motor 32 KWPower Input To The Pump 731 KWEfficiency Of The Pump Alone 81%Overall Efficiency Of Pump & Motor 77.6 %16.4CEP Suction Strainer

Make MultiplexHole size 400

16.4.1 Operating Condition NB 503Fluid CondensateTemp 50CFlow rate 970

16.4.2 Performance ConditionAlteration rating 315 Max.Clean Pr. Drop 0.03 KscDirty Pr. Drop 0.05 Ksc (50% Clogged condition)



16.4.3 Design ConditionDesign code ASME Sec-VII Div. 14Pr. 8.0 + FVTemp 65CHyd. test 12 Ksc 30 minEmpty/flooded wt 1350/2210 KgBasket (OD+Length+Area) 730*780 & 29417 cm2 16.5Sealing water requirement Flow 0.55 M3/Hr.Pressure 3 to 4 ataTemperature 48-65 oC

17 TURBINE DRIVEN BOILER FEED PUMP 17.1Booster pump

Manufacturer BHELType FA IB 75Direction of rotation (Viewed on NDE) AnticlockwiseLiquid pumped DM WaterS.G. at suction temperature 0.9045Suction temperature 162.7 Dec CNPSH 4.5 KSCDifferential Head (design) 205 MFlow rate 990.0 m3/hrEfficiency 81.50%Speed 1495 rev/mPower absorbed 613 KW

17.2Main pump

Manufacturer BHELType FK 4E 36Suction Flow 990 cum/hrKicker Flow 150cum/hr+ 30cum/hrSuction pressure 6.85 kg/cm2

Design Head 205.0 kg/cm2

Kicker Head 209.0 kg/cm2

Speed 5465 rpmEfficiency 81%

Thrust BearingManufacturer Mitchell BearingType Double thrust.Mechanical seal Bergman

17.2.1 Direction of rotation from Booster Pump to BFPTurbine CCWBFP CCWBP CW



17.3 Turbine

Equipment Turbine

Maximum output 7504 KWDesign rating 5748 KWSpeed 5260 RPMSpeed range 1494-5750 RPMMax Initial Steam Pr 6.32 ata.Pemissible steam pr 11.3 ata(without deviation)Initial steam Temperature 288.4 0 C.Max Initial steam Temperature 320.0 0 C.(without limitation)

Exhaust pressure 0.105 ataTrip Speed 6012Critical Speed 7550 17.4TDBFP- Gear Box (Ref. 0-311-01-02121) Sr. No 30/5875 to 30/5879Input Speed 5465 rpmOutput Speed 1495 rpmRatio 3.655Power transmission 822 HP/613 KWNormal power torque @ LS Shaft 3916 mNExceptional torque@ LS Shaft 7832 mNRecommended Lube Oil ISO VG 46Max. Oil flow 30 LPM at KPA & 50 CHeat rejection rate 17.6KWTurbine lube oil strainer size 250 Turbine lube oil Strainer Mat. Stainless Steel 17.5Oil system

Lube oil pump 2 NosEmergency Oil pump 1 NoJacking Oil Pump 1 No

Oil vapour extractor fans 2 Nos

17.6Oil Vapor Extractor Fans

Nos 2 per PumpMounting Tank TopType Centrifugal, Direct MountedRating 0.37 KW , 2800 RPMMake Crompton GreavesFull load current 0 .79 A

17.7Oil Pumps Specification Aux. Oil PP DC Oil PP Jacking Oil Pump Oil Transfer



PumpNumber 2 1 1 1Make Tushako, india KSB Delta Corp. Delta Corp.Type Screw Centrifugal Gear (HPG2A) R20-DGCapacity (lpm) 2500 lpm 24.9 m3/hr 9

suc pr-7.0 Ksc50.8 at 40C58 at 70C

Rated Head(Ksc)

11.6 51.2 mdisch pr-4.5

100.0 3.0

Speed (RPM) 1440 2900 1440 1400Drive A.C. Motor D.C. Motor A.C. Motor A.C. MotorMotor Make Crompton Greaves Crompton Greaves Crompton Greaves NGEF

Voltage (V) 415 220 (armature) 415 415Power (KW) 90 15.0 3.7 1.1Rated Current 147 79 7.6 2.5DORMotor

CW from DE side

CW from DE side

CW fromNDE side

CW fromDE side

Speed (rpm) 1480 2900 1440 1400

Motor bearing 6318-C3 6311-2RS 6306ZZ6205ZZ

Efficiency 94.5 - - -

17.8Oil Purifier (Centrifuge)Make Alfa LavalType MAB 205Motor 5.5KW, 415V, 10.4 Amp., 1445 RPMOperating speed 8725 RPMRated capacity 2.4 M3/Hr.Indirect oil heater 415 V, 3 phase, 50 HzHeater capacity 60 KWFeed pump motor make Bharat BijleeMotor specification 2.2 KW, 415 V, 4.6 Amp Running up time 1.5-2.5 minStopping time 2 min with break applied

17.9TDBFP Governing System

17.9.1 Governing Rack

Input Oil Pressure 8 barPower Oil Pressure 8 barType of Governing I/H Converter (Current / Hydraulic)Type of Sec Oils HP for MCV & LP for ACVO/P Secondary Oil Pr 1.5-4.5 bar (corresponding to 4-20mA) ESV Test Oil Pr 8 barOver Speed Test Oil Pr 3.2 bar



17.9.2 Emergency Stop Valve (ESV)

Type Latching Type, Fast ClosingOpening Time 1-2 minClosing Time 60 mSecOperating Oil Pr 8 barOpen / Close Operation Solenoids

17.9.3 Main Control Valve (MCV)

No of Valves 5Controlling Mechanism Bush Groove DepthMaximum servomotor travel 130 mmStart of operation 1.5 bar of HP Sec Oil PrFull Open Condition 4.5 bar of HP Sec Oil Pr

17.9.4 Aux. Control Valve (ACV)

No of Valves 1Controlling Mechanism Seat OverlapMaximum servomotor travel 70 mmStart of operation 1.5 bar of LP Sec Oil PrFull Open Condition 4.5 bar of LP Sec Oil Pr

17.9.5 Accumulators

No of Accumulators 2 per PumpOperating Pressure 6.5 barOperating point Governing Oil LineCapacity 35 Ltrs

17.9.6 Hydraulic Pressure AccumulatorRef no 3-11430-02000 Designation Hydraulic Pr. Accumulator (2 lit)Gas Pressure 2 BarFilling Gas NitrogenNormal operating Pr. 2.5 Bar to 6 BarMax. Operating Pr. 8 Bar

Working Medium Turbine oil of 21 to 31 centistokes at 50C Or Fire

Resistance Fluid 21 to 27 centistokes at 50CMax. Allowable operating Pr 100 Bar

Normal working Temp. 65CAllowable Range of operation 0C to 80 C

17.9.7 Material Membrane VITON



Accumulator-Body C22.8N

17.10 TDBFP Twin Oil Cooler (Drg no3-165-01-00277)

17.10.1 Design Data Design Data Shell Tube Make BHEL BHELDesign Pr. Ksc 13.5 10Test Pr. Ksc 17.55 13.0Pr drop 0.65 0.8Design Temp. C 100 100Corrosion allow mm 1.6 1.6Stress Relieving NO NORadiography NIL NILNo. of Passes 1 4Medium Oil WaterJoint efficiency 0.7 0.7Surface area/cooler Sq.m 85 No. of Tubes Per Cooler 436Tube Length mm 4000Tube Size of OD*Thk mm 15.875*1.24Pitch/Type mm 19.05/No. of Baffles per cooler 25Baffle Pitch mm 141 Heat Duty Kcal/hr 281688Oil Qty. m3/hr 47.6Water Qty. m2/hr 100Oil Side Temp C 60/45Water side Temp C 38/41Over all Heat 356 Kcal/hr m2 C

17.10.2 WeightsEmpty Weight Kg (Both code) 5700Working Weight do 6800Flooded weight do 7200

17.10.3 Materials shell CS, SA 106Gr B tubes SS(SA 249 TP 304) 17.11 Flexible Coupling (Drg no8GBL-219)

17.11.1 SpecificationPower KW 900Speed rpm 1486Operating Torque Kgm 502Max. Torque Kgm 623



Max. Inst. Torque Kgm 1246

17.11.2 Coupling capacityContinuous Torque Kgm 1061Peak Torque Kgm 2122Short circuit Torque Kgm 3925Inertia (WK2) kgm2 0.55Torsional Stiffness Kgm/rad 0.281*10(1/3 shaft penetration)Balance G 2.5 ISO 194017.12 Power pack assembly

Make Baldor, USASpecification M35A03X419HP 2Volts 220/380/415-440Amps 5.6/3.2/2.9-2.8Rpm 2850Frame 145TC

17.13 Operating condition TDBFP BOOSTER P/P Emergency

ConditionRunOut

Best eff Designcapacity

EmergencyCondition

RunOut

Best eff Designcapacity

Capacity 970 1100 855 990 970 1100 855 990Head 2308 1787 1982 2025 227 198 193 205Temp. 161.1 146.6 161 162.7 161.1 146.6 161.0 162.7Sp Gr. 0.9062 0.9198 0.9062 9045 0.9062 .9198 0.9062 0.9045Efficiency 81% 81% 81% 81 81 81.5 79.5 81.5Power(KW)

6823 6080 5229 6098 671 670 512 613

Speed(rpm

5740 5430 5260 5465 1570 1486 1439 1495

NPSHRM/c

52 56 43 50 4.6 5.1 3.8 4.5

18 MOTOR DRIVEN BOILER FEED PUMP 18.1Booster pump Manufacturer BHEL Hyderabad 2003

Type FA IB 75Pump no P2002-040

Direction of rotation (Viewed on NDE) AnticlockwiseLiquid pumped DM WaterS.G at suction temperature 0.9045

Suction temperature 162.7 Dec CNPSH 4.5 KSCDifferential Head (design) 205 MFlow rate 990.0 m3/hrEfficiency 81.50%Speed 1495 rev/mPower absorbed 613 KW



18.2Main pump

Manufacturer BHEL Hyderabad 2003Frame FK4E 36 Pump no P2002-052Suction Flow 990 cum/hrKicker Flow 150cum/hr+ 30 cum/hrSuction pressure 6.85 ataDesign Head 2025 mKicker Head 209.0 ataSpeed 5465 rpmEfficiency 81%Temperature 162.7

Thrust bearingManufacturer Mitchell Bearing

Double thrust.Mechanical seal

Manufacturer Eagle Poonawala, Pune 18.3 Motor Manufacturer BHELType 3 phase synchronousPower 10 MWVoltage 11 kvCurrent 601.5 ampsSpeed 1495 rpm 18.4Hydraulic coupling Manufacturer M/s. VOITH, GermanyType R 18 KGS 14 APICode Bharat S 138 RIHAND

Hydraulic oil type HLP32 to DIN 51524Journal brg. Type PlainThrust brg. Type tilt

Rotation seen in direction of power flow Input shaft CCW

Output shaft CCWGear ratioU1 109/32

Gear ratio U2 62/53Full load slip 2.3%Primary Speed 5092 rpmSecondary speed 5102 RPMMax. Output speed 5820 rpmOil tank filling 2.50 cum.Power Required 6945 KWLube oil flow 300 l/min at 2-2.5 KSC pr

Full load slip 2.0 %Max. Output speed 6440 RPMRegulation range 4:1 downwardsBearing temp. < 90oC



18.5Flexible coupling (91069-00) Motor HC

18.5.1 SpecificationMake Euro flex Transmission Pvt. Ltd.Power 10000 KWSpeed 1494 rpmOperating Torque 5249Max. Torque (Kg-m) 6650Max. Ins. Torque 13300

18.5.2 Coupling Capacity Continuous torque 91.7 KN-mPeak torque 183Short cut torque 311Inertia 10.3518.6Oil Pump Auxiliary Oil Pp Main Oil PpManufacturer VOITH/Germany VOITH/GermanyType Gear CentrifugeNo. of PP. One OnePump Drive AC Motor Shaft drivenRated head (bar) 4.0 4.0Rated capacityMotor typePowerRated speedVoltageProtection

2950 lpmDE 200LA230 KW2950 rpm415 VIP55

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18.7Lubricating Oil Specification Oil supplier Indian Oil CorporationBrand name Servo HLP32Capacity of lube oil tank 2.5 M3Total lube oil flow rate( For pps, coupling & motor) 300 l/Min.Lube oil pr. 2.5 barControl oil pr. 3.5 barWorking oil pr. 2.5 bar (Max.)Working oil flow rate 1300 l/Min.

18.8Oil Coolers Working Oil Lub Oil Type (Make) Shell/Tube (VOITH) Shell/Tube (VOITH) No. of coolers 2 X 100% 2 X 100% Oil filling for one heat exchanger 148 L/32L 91 L/63L Oil flow rate 78/120 M3/hr. 51/75 M3/hr. Oil temp. Inlet to cooler 95 /38oC 65/38 oC Oil temp. Outlet of cooler 58/48 oC 50/42 oC Cooling Water flow 120 M3/hr. 75 M3/hr.



Cooling Water Inlet temp. 38 oC 38 oC Cooling Water Outlet temp. 48 oC 42 oC Oil side Pr. drop (bar) 0.54 0.41 Maximum allowable pr 16/10 16/10 18.9 Lub Oil Requirement In Brgs

BFP Booster Pp Journal Thrust Journal Thrust Oil Flow (M3/hr.) 0.42 13.44 0.3 0.72 Oil pr. (bar) 2.5 2.5 2.5 2.5 Maxm. Bearing temp (oC) 100 80 80 65 18.10 Oil Purifier For MDBFP

Make Alfa Laval Type Portable / MAB 103 Motor Make Bharat Bijlee Ltd. 18.11 Operating parameter Equip. Operating Speed Critical Speed Design Best eff Run

outEmer. First Second

New Wornout

New Wornout

BFP 5465 5245 5425 5775 9124 8118 12093 11926 Booster Pump 1495 1495 1495 1495 4632 4523 8530 8490 Motor 1495 1495 1495 1495 --- --- --- --- HC I/P Shaft 1495 1495 1495 1495 --- --- --- --- HC O/P Shaft 5465 5245 5425 5775 --- --- --- ---

18.12 BFP Conical Strainer

18.12.1 Operating Condition BFP BPNB 400 450Fluid Feed water ---Flow (m3/hr) 1240 1240

18.12.2 Performance Condition BFP BPAlteration rating 195 315Clean Pr. Drop 0.03 0.15Dirty Pr. Drop 0.05 0.15 (50% Clogged) Condition)

18.12.3 Design Condition BFP BPNB 400 450Design code ASME Sec-VII Div. 14Temp 190C 190CBasket (OD*L) 420*2280m 570*760mGross area 30390 cm2 22067 cm2



Empty/flooded wt 1200/1725 2350/2875

19 DEAERATOR AND FST 19.1Deaerator Header AssemblyType Spray cum TrayDiameter x Thickness ID3000X 16 mmHeader length 10564 mmDesign pressure 9 ksc & full vacuumDesign Temperature 360OCOperating pressure 6.59 KSCOperating Temperature 167.5 OCTest Pressure 11.5 KSCTest Temperature AmbientCondensate inlet Qty 1272.885 tphNo Of Trays 576No. Of spray valves 108Spray valve capacity 15 T/hrDissolved Oxygen in Feed water 0.005 cc/litCond. Temp/enthalpy/pr 124.7/125.3/6.9

19.1.1 Materials

Header & Dished End SA 516 GR 70 Trays SA 240 TP 304 Tray Support SA 240 TP 304 Tray removal openings & Internal pipes SA 106 GR B

Packing CAF 9 19.2Feed water storage Tank Inside dia x thickness 3600 X 20 mm

Total Length 32425 mmSteam inlet quantity 84.774 T/hrInlet steam pr/temp 6.9 Ksc/288 CSafety valve set pr 6.9 KscInlet steam enthalpy 725.7 Kcal/KgDesign Pressure 9 ksc & full vacuumDesign Temperature 360OCFeed water out pressure/temp 6.8 ksc/163Feed water enthalpy 164.5Kcal/kgFeed water quantity 1625.334 T/hrTest Pressure 11.7 KSC

Test Temperature AmbientCapacity (NWL to LWL) 170

19.2.1 Materials Storage Tank Shell & Dished End SA 516 GR 70 Internal Nozzles SA 106 GR B Cover for Manholes SA 105

19.2.2 Weights



Storage Tank & Header Dry Kgs. 110000Storage Tank & Header in operation Kgs. 318000Storage Tank & Header flooded Kgs. 490000

19.3DEAERATOR SAFETY VALVES Safety Valve Design Lift Pr Lift Pr Reset Pr

(Kg/Cm2) (Kg/Cm2) (Kg/Cm2)SV-1 (On FST / DM Plant Side) 9.0 9.15 7.5SV-2 (On FST) 8.5 8.7 7.0SV-3 (On FST) 8.0 8.25 6.25SV-4 (On FST) 9.0 9.25 7.25SV-5 (On Dea / Turbine Side) 9.0 9.0 7.25SV-6 (On Dea / Boiler Side) 8.5 8.5 8.5

20 SEAL OIL SYSTEM 20.1 AC Seal oil pump (Air side) 2no full capacity

20.1.1 Pump specification Kind of pump Screw pumpType 3-52/54-IBSCS 1X2 (DELTA)Capacity 258 lpmDischarge pr 12 ksc

20.1.2 Motor specification Make CGLRating 7.5 KWVoltage/frequency 415 V/50 hzCurrent 15.6 ASpeed 1440 rpmType of insulation P55 20.2 DC Seal oil pump (Air side)

20.2.1 Pump specification Kind of pump Screw pumpType 3-52/54-IBSCS 1X2 (DELTA)Capacity 258 lpmDischarge pr 12 ksc

20.2.2 Motor specification Motor TDC 225L (KEC)Rating 8.5KWVoltage/frequency 220 V DCCurrent 67 ASpeed 1450 rpm



Type of insulation IP55No of pump No of gas side 2 no full capacity 20.3 Seal oil cooler (Air side)Type surface Make BHEL-HARDWARSurface area (m2) 19.1 Oil flow 1.16 dm3/sHeat dissipating capacity 140 KWOil inlet temp 70 COil outlet temp 50 COil pr drop 0.833 barCooling water flow 35 m3 /hrCooling water inlet temp 36 CCooling water outlet temp 39.4 CWater pr drop 6.8 mWC 20.4Seal oil cooler (Gas side)Type surface Make BHEL-HARDWARSurface area (m2) 19.1m3Oil flow 2.17dm3/s

Heat dissipating capacity 90 KWOil inlet temp 70 COil outlet temp 50 COil pr drop 0.85 barCooling water flow 22 m3 /hrCooling water inlet temp 36 CCooling water outlet temp 39.5 CWater pr drop 7.1 mWCTube side deign pressure 16kscShell side deign pressure 16ksc 20.5AS seal oil filter Filter-1 Filter-2 Make BOLL & Kirch BOLL & Kirch F (m) 100 100 20.6H2 seal oil Filter Filter-1 Filter-2 Make BOLL & Kirch BOLL & Kirch F (m) 100 100

21 TG LUBE OIL SYSTEM 21.1 Lube Oil pumps specification

21.1.1 Pumps specification

MOP AOP DC EOP JOP Number 1 2 1 AC: 2 DC: 1



Make BHEL Mather+platt Mather+platt All weiler All weiler

Type 350 m/hr 5/6 EHLG 4/9KL-70

SDF/A80R466-9-W112

SDF/A80R466-9-W112

Capacity(LPM)

361 1800 111-158 111-158

Disch. Pr.(bar)

8.4 75.7m 2.76 178 178

Speed(RPM)

3000 2970 1425 2900 2900

Drive Turbine AC Motor DC Motor AC Motor DC Motor

21.1.2 Motor specification

Make

- CromptonGreaves

CromptonGreaves

ABB CromptonGreaves

Voltage (V) - 415V 220V 415V 220VMotor Power (KW) - 110 13 76 50Rated Current (Amp.) - 173 97 122 315DOR from top - Clockwise Clockwise Clockwise ClockwiseInsulation F IP55 IP55 F

21.2 Materials

Shell, Channels C.S. SA 516 GR 70 C.S. SA 516 GR 70 C.S. SA 516 GR 70Tube plate & covers C.S. SA 516 GR 70 C.S. SA 516 GR 70 C.S. SA 516 GR 70Flanges *** C.S. SA 105 C.S. SA 105Support plate C.S. IS 2062 C.S. IS 2062 C.S. IS 2062Tubes S.S. SA 688 TP 304 S.S. SA 688 TP 304 S.S. SA 688 TP 304Condensate Inlet / Outletpipe

C.S. SA 106 GR B C.S. SA 106 GR B C.S. SA 106 GR B

Steam inlet pipe C.S. SA 106 GR B C.S. SA 106 GI B C.S. SA 106 GR BImpingement plate S.S. SA 240 TP 304 S.S. SA 240 TP 304 S.S. SA 240 TP 304

22 HP HEATERS 22.1HPH-5A & 5B(1230-001-04HY-PVM-B-026) Shell Tube

Design Pr.

Date post:	10-Nov-2015
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